GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 SSR 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Flushing

Tools Required

    • J 43600 ACR 2000 Air Conditioning Service Center
    • J 45268 A/C Flush Adapter Kit
    • J 41447 R134A Leak Detection Dye
    • J 42220 Universal 12V Leak Detection Lamp

Important: Flushing with the J 43600 is not intended to remove metal from the A/C system.

Flushing is intended to remove the following:

    • Contaminated polyalkylene glycol (PAG) oil
    • Desiccant, following a desiccant bag failure
    • Overcharge of PAG oil
    • Refrigerant contamination

Forward Flushing Setup

    Important: Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil.


    Object Number: 1162447 Size: SH

    Important: Inspect and lubricate the J 45268 fitting O-rings.

  1. Install both J 45268-9 onto the J 45268-2.
  2. Install the J 45268-7 onto the suction side of the J 45268-2.
  3. Install the J 45268-8 onto the discharge side of the J 45268-2.

Reverse Flushing Setup

    Important: Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the condenser/receiver dehydrator assembly when the A/C flush is complete and perform the following procedure:


    Object Number: 1211671 Size: SH

    Important: Inspect and lubricate the J 45268 fitting O-rings.

  1. Install both J 45268-9 onto the J 45268-2.
  2. Install the J 45268-8 onto the suction side of the J 45268-2.
  3. Install the J 45268-7 onto the discharge side of the J 45268-2.

Flush Procedure

    Important: Warmer engine or ambient temperatures decreases the refrigerant recovery time during the A/C flush procedure.

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the thermal expansion valve (TXV). Refer to Thermal Expansion Valve Replacement .

    3. Object Number: 1229969 Size: SH
  3. Install the stud (2) onto the J 45268-115 (1).
  4. Install new sealing washers onto the evaporator core. Refer to Sealing Washer Replacement .
  5. Install J 45268-115 in place of the TXV.

    6. Notice: Refer to Fastener Notice in the Preface section.

  6. Install TXV mounting bolts.

    7. Tighten
    Tighten the bolts to 7 N·m (62 lb in).

  7. Install new washers onto the rear evaporator line assembly. Refer to Sealing Washer Replacement .
  8. Connect the rear evaporator line assembly to the J 45268-115.
  9. Install the TXV block fitting nut.

    10. Tighten
    Tighten the nut to 27 N·m (20 lb ft).

  10. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .

    11. Object Number: 787687 Size: SH

    Important: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter.

  11. Service the filter with AC Delco P/N GF 470, before each flush.

    12. Object Number: 1198495 Size: SH

    Important: Install new sealing washers onto the compressor hose assembly. Refer to Sealing Washer Replacement .

    Assure that the suction and discharge ports on the J 45268-2 correspond to the suction and discharge ports on the compressor hose assembly.

  12. Install the J 45268-2 to the compressor hose assembly.

    13. Object Number: 1162507 Size: SH
  13. Connect the J 45268-1 flush filter to the J 45268-7 flush adapter.
  14. Connect the blue hose from the J 43600 to the J 45268-1 flush filter adapter.
  15. Connect the red hose from the J 43600 to the J 45268-8 flush adapter.

    16. Important: Close the valve on the external refrigerant tank, before starting the flush process.

  16. Flush the A/C system. Follow the instructions supplied with the J 43600 .
  17. Disconnect the red hose from the J 43600 to the J 45268-8 flush adapter.
  18. Disconnect the blue hose from the J 43600 to the J 45268-1 flush filter adapter.
  19. Disconnect the J 45268-1 flush filter from the J 45268-2 flush adapter.
  20. Remove the J 45268-2 from the compressor hose assembly.

    21. Object Number: 1230334 Size: SH

    Important: Flushing will remove all the PAG oil from the A/C system.

    The A/C system must be replenished with the correct amount of PAG oil.

  21. If you will reinstall the removed A/C compressor, perform the following procedure:
    22. 21.1. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor.
    21.2. Add the total system capacity of PAG oil to the A/C compressor. Refer to Refrigerant System Capacities .

    Important: A new service compressor is shipped with a full charge of PAG oil. Refer to Refrigerant System Capacities .

  22. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  23. Remove the TXV block fitting nut.
  24. Disconnect the rear evaporator line assembly from the J 45268-115.

    25. Object Number: 1229969 Size: SH
  25. Remove the TXV bolts retaining the J 45268-115.
  26. Remove the J 45268-115.
  27. Inspect the TXV for debris. Clean or replace as needed.
  28. Install the TXV. Refer to Thermal Expansion Valve Replacement .
  29. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .

    30. Important: Flushing will remove the fluorescent leak detection dye from the A/C system.

  30. Add one bottle of J 41447 .
  31. Leak test the fittings using J 42220 .